The document summarizes the work done at the Diesel Locomotive Works in Varanasi, India. It describes the various workshops that manufacture and assemble parts for diesel locomotives, including the heavy welding shop, heavy machine shop, rotor shop, and paint shop. The heavy welding shop performs various arc welding techniques to join metal parts. The heavy machine shop uses machines like lathes and CNC to cut and shape metal parts. The rotor shop focuses on manufacturing and assembling turbochargers that provide fresh air to the locomotive engines. After assembly, the locomotive parts are sent to the paint shop for final painting and markings.

1. DIESEL LOCOMOTIVE WORK
SHOP
Submitted by
SHIVESH SINGH
◦ Roll-110106259
◦ Branch- Mechanical D
◦ 4th Year

2. INTRODUCTION
Diesel locomotive works was established in 1961 in Varanasi.
Asia's Second largest Railway diesel engine production industry.
By The End of March 2005 DLW has Manufactured 4707 Locomotive .

3. How does it work?
It converts the chemical energy available in fuel into
mechanical energy
This mechanical energy moves pistons up and down inside
cylinders
This motion creates the rotary motion needed to turn the
wheels of a train forward
It uses a four stroke combustion cycle: intake,
compression, combustion, and exhaust

4. TYPES OF SHOPS
observed
1. HEAVY MACHINE SHOP
2. HEAVY WELD SHOP
3. ROTOR
4. PAINT SHOP

5. TYPES OF WORKSHOPS
ALLOTED.
HWS (heavy welding shop)
This is one of most sophisticated workshop.
Types of welding performed are:-
ARC welding:- An electric arc between work piece and electrode produces
heat , which is sufficient enough to melt the work piece together.
Current requirement of 5 to 500 ampere.
Voltage is ranged from 20 to 30 volts, either AC or DC.
Both current and voltage are determined on basis of material thickness.

6. CLASSIFICATION OF ARC
WELDING
SHEILD METAL ARC WELDING……..(stick SMAW)
GAS METAL ARC WELDING………….(GMAW)
FLUX CORE ARC WELDING…………..(FCAW)
GAS TUNGSTEN ARC WELDING…..(GTAW)

7. Related terms
ELECTRODE – Place where current passes from welder to workpiece.
It is of two types:-
1) Contact
2) Non Contact
Atmospheric protection
1) Flux
2) Shielding gas

9. HEAVY MACHINE SHOP
Various machining process are done in this shop.
Machines like lathe machine, CNC etc. are available at this shop.
Mainly CNC are used because of easiness they provide. Various cutting
,shaping process are done by coding commands. It is an automatic device
which works on numerical coding.
is a machine tool which rotates the work piece on its axis to perform
various operations such as cutting, knurling ,drilling,
or deformation facing, turning, with tools that are applied to the work
piece to create an object which has symmetry about an axis of rotation.

11. ROTOR SHOP
Deals with manufacturing of turbocharger.
Turbocharger is important part of diesel locomotives.
Basically manufacturing, assembly and subassembly of
turbo charger takes place. Outer casing is made in
HMS(Heavy Machine Shop)
Turbocharger is used to provide fresh air to the locomotive.
Used to increase power and efficiency of engine.
No extra motor or generator is used for functioning of
rotor. It works with help of exhaust gases.

12. COMPONENTS OF
TURBOCHARGER
1) IMPELLAR
2) INDUCEOR
3) NOISE PIECE
4) STUD ROTOR
5) NUT
6) WASHER
7) THRUST WASHER
8) KEY
9) OIL SLINGER
10) TURBINE DISC
11) TURBOSHAFT
12) LOCKPLATE

13. Assembly of turbocharger is done by dividing it
into three parts:-
1) rotor- It is inlet part of turbocharger which
consists of many sub parts like rotor disc,
washer, locknut etc.
2) compressor- Combination of impeller and
inducer. Impeller is made of al alloy. These
parts are used for sucking fresh air from
environment.
3) casing- casing is made of mild steel and
special coating is done on it so as to resist the
heat.

14. LOCO PAINT SHOP
After the chassis of bogie and engine is made they are sent
for final work of painting. Loco painting is done by spray
paint. Skilled workers are employed who can make
markings take shape and size under consideration.
Spray paint gun

15. TTHHAANNKK YYOOUU